Fence rail bracket with tool-less fasteners

ABSTRACT

A fence rail bracket assembly for mounting a fence rail to a fence post includes a mounting bracket and at least one retainer clamp that locks to the bracket without using any tools. The mounting bracket mounts to the post, has a bottom wall that supports the rail, and has two sidewalls that receive the rail between them. At least one sidewall coupling element interlocks with at least one clamp coupling element to lock the clamp to the bracket and thereby secure the rail on the bracket. In example embodiments, the bracket assembly includes two clamps each having one coupling element, one clamp having two coupling elements, push-lock coupling elements, slide-lock coupling elements, and angular slide-lock coupling elements.

CROSS-REFERENCE TO RELATED APPLICATION

The benefit of the filing date of U.S. provisional patent application Ser. No. 61/172,082, filed Apr. 23, 2009, entitled FENCE RAIL BRACKET WITH TOOL-LESS FASTENERS, is hereby claimed, and the specification thereof is incorporated herein by this reference.

TECHNICAL FIELD

The present invention relates generally to fence systems and, in particular, to mounting brackets for attaching fence rails to fence posts.

BACKGROUND OF THE INVENTION

Typical fence systems include vertical posts, horizontal rails extending between the posts, and sometimes vertical pickets mounted to the rails. Fence systems with these components molded of vinyl or another plastic have become popular because of their durability and low cost. In such fence systems, plastic brackets are mounted to the posts to support the rails. The brackets are usually mounted to the posts by metal screws, and then metal screws are inserted through holes in the brackets and into the rails to secure the rails to the brackets. The bottom walls of the brackets support the weight of the rails, the sidewalls of the brackets hold the rails in place on the bottom walls, and the screws that secure the rails to the brackets keep the rails from being upwardly dislodged from the brackets. These screws are typically made of very high grade aluminum so that they will not corrode and stain the fencing. But such screws can be expensive.

Accordingly, it can be seen that there is a need in the art for a better way to mount fence rails to fence posts. It is to the provision of a solution meeting these and other needs that the present invention is primarily directed.

SUMMARY OF THE INVENTION

Generally described, the present invention in one aspect provides a fence rail bracket assembly for mounting a fence rail to a fence post. The bracket assembly includes a mounting bracket and at least one retaining clamp that locks to the bracket without using any tools. The mounting bracket mounts to the post, has a bottom wall that supports the rail, and has two sidewalls that receive the rail between them. At least one sidewall coupling element interlocks with at least one clamp coupling element to lock the clamp to the bracket and thereby secure the rail on the bracket. In example embodiments, the bracket assembly includes two clamps each having one coupling element, one clamp having two coupling elements, push-lock coupling elements, slide-lock coupling elements, and angular slide-lock coupling elements.

The specific techniques and structures employed by the invention to improve over the drawbacks of the prior art and accomplish the advantages described herein will become apparent from the following detailed description of example embodiments of the invention and the appended drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a fence rail bracket assembly according to a first example embodiment of the present invention, showing a mounting bracket mounted to a fence post and a fence rail being mounted to the bracket by retainer clamps.

FIG. 2 is a side view of the bracket assembly taken of FIG. 1.

FIG. 3 is a perspective view of one of the clamps of FIG. 1.

FIG. 4 is a front view of a retainer clamp and a portion of a mounting bracket of a bracket assembly according to a second example embodiment, with the clamp not having any visible interlocking structures when installed.

FIG. 5 is a front view of a retainer clamp and a portion of a mounting bracket of a bracket assembly according to a third example embodiment, showing the clamp having a female coupling element and the bracket having a male coupling element.

FIG. 6 is a front view of a retainer clamp of a bracket assembly according to a fourth example embodiment, showing two coupling elements on the single clamp.

FIG. 7 is a front view of a retainer clamp and a portion of a mounting bracket of a bracket assembly according to a fifth example embodiment, showing sliding coupling elements.

FIG. 8 is a side view of the bracket assembly taken of FIG. 1, showing the clamp being slid onto the mounting bracket.

FIG. 9 is a side view of a retainer clamp and a portion of a mounting bracket of a bracket assembly according to a sixth example embodiment, showing angled sliding coupling elements for tightening down the clamp onto the rail in the bracket.

FIG. 10 is a front view of a clamp and a portion of a mounting bracket of a bracket assembly according to a seventh example embodiment, showing interlocking sliding coupling elements.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Referring to the drawings, FIGS. 1-3 illustrate a fence bracket assembly 10 according to a first example embodiment of the present invention. The bracket assembly 10 is shown in use in a fence system 12 to mount a lateral fence rail 14 to an upstanding fence post 16, the rail and the post both being molded of vinyl or another plastic. It will be understood, however, that the bracket assembly 10 can be adapted for use in other types of fence systems, including banisters, handrails, picket fences, and fence systems made of wood, metal, and/or other materials.

The bracket assembly 10 includes a mounting bracket 18 and two retainer clamps 20 that lock to the bracket, without using any tools, to secure the rail 14 on the bracket. The mounting bracket 18 and the clamps 20 can be packaged together and sold as a kit, or they can be provided individually.

The mounting bracket 18 is preferably molded of vinyl or another plastic in the manner of conventional fence rail brackets made by U.S. Fence and sold nationwide at The Home Depot. In the depicted embodiment, the mounting bracket 18 includes two upstanding sidewalls 24, a rear wall 26 extending inwardly between and/or outwardly from the sidewalls, and a bottom wall 28 extending at least partially between the two sidewalls. The bottom wall 28 has a support surface 30 that supports the weight of the rail 14 and any vertical loading applied to the rail. The sidewalls 24 receive the rail 14 between them to hold the rail in place on the support surface 30. The sidewalls 24 and the bottom wall 28 cooperative to form an upper access opening 22 through which the rail 14 can be lowered (or otherwise non-axially inserted) onto the bracket 18. And the rear wall 26 has apertures for receiving screws 32 for mounting the bracket 18 to the post 16.

In alternative embodiments, the sidewalls and the bottom wall of the bracket form a curve or other shape for use in mounting a curved or other-shaped rail to it, and/or the rear wall of the bracket forms a curve or other shape for use in mounting to a curved or other-shaped post. In other alternative embodiments, more or fewer than two of the clamps are provided, the access opening is located at other than the top of the bracket, the access opening is formed by other portions of the bracket, the bracket includes other elements for mounting to the post, and/or the bracket is made of wood, metal, or another material.

The depicted mounting bracket 18 has dimensions of about 2 inches by 3 inches for use with a rail having cross-sectional dimensions of about 2 inches by 3 inches. (In practice, the rail and bracket have actual dimensions of about 1¾ inches by 2¾ inches, as is common in the industry). In other alternative embodiments, the mounting bracket has other shapes and sizes that are selected based on the shapes and sizes of the rails and posts the mounting bracket is to be used with.

In addition, the mounting bracket 18 and the retainer clamps 20 include mating coupling elements 32 and 34, respectively. The mating coupling elements 32 and 34 interlock without the use of any tools to secure the clamps 20 to the bracket 18. In the depicted embodiment, the mounting bracket coupling element 32 is a female part and the clamp coupling element 34 is a male part that us received by the female mounting bracket coupling element. In addition, the clamp coupling element 34 has one or more resiliently deflectable barbs or other locking structures 36 on an inwardly facing surface 38 a and an outwardly facing surface 38 b (see FIG. 3). And the bracket coupling element 32 has one or more resiliently deflectable barbs or other locking structures 40 on two internal surfaces that interlock with the locking structures of the mounting bracket coupling element 32. When the clamp 20 is pushed down onto the bracket 18 (as indicated by the directional arrows of FIGS. 1 and 2), the locking structures 36 and 40 interlock together to secure the male clamp coupling element 34 within the female mounting bracket coupling element 32, thereby locking the clamp onto the bracket.

In alternative embodiments, the locking structures of only one of the coupling elements are resiliently deflectable and the locking structures of the other one of the coupling elements are fixed shoulders that do not deflect. In other alternative embodiments, the female coupling element is defined by two walls that resiliently deflect apart/open to receive the male coupling element and then resiliently deflect back/closed to retain the male coupling element. And in still other alternative embodiments, the coupling elements each include only a single locking structure (e.g., one resilient rib and one groove).

Furthermore, the retainer clamps 20 each include a cover wall 44 defining a retaining surface 42 that at least partially blocks the access opening 22 of the bracket 18 when the clamps are locked in place on the brackets 18. The clamp retaining surface 42 need not completely block the access opening 22. Rather, the clamp retaining surface 42 need only obstruct the access opening 22 sufficiently to prevent the rail 14 from fitting through the access opening and being removed from the bracket 18.

FIG. 4 illustrates a retainer clamp 120 and a portion of a mounting bracket 118 of a bracket assembly according to a second example embodiment. The clamp 120 and the mounting bracket 118 are similar to those of the first example embodiment. In this embodiment, however, the clamp coupling element 134 has locking structures 136 on the inwardly facing wall 138 a, but does not have any locking structures on the outwardly facing wall 138 b. Thus, there are no locking structures that would be visible if the clamp coupling element 134 were not pushed all the way down into the bracket coupling element 132.

FIG. 5 illustrates a retainer clamp 220 and a portion of a mounting bracket 218 of a bracket assembly according to a third example embodiment. The clamp 220 and the mounting bracket 218 are similar to those of the first example embodiment. In this embodiment, however, the clamp coupling element 234 is a female part and the bracket coupling element 232 is a male part that is received by the female clamp coupling element. In addition, the male bracket coupling element 232 may be outwardly offset to leave a gap for the inside wall of the female clamp coupling element 234.

FIG. 6 illustrates a retainer clamp 320 of a bracket assembly according to a fourth example embodiment. The clamp 320 is similar to that of the first example embodiment. In this embodiment, however, a single clamp 320 includes two coupling elements 334 and the cover wall 344 extends between the two coupling elements. Preferably, the cover wall 344 completely covers and obstructs the access opening of the bracket.

FIGS. 7 and 8 illustrate a retainer clamp 420 and a portion of a mounting bracket 418 of a bracket assembly according to a fifth example embodiment. The clamp 420 and mounting bracket 418 are similar to those of the fourth example embodiment just described. In this embodiment, however, the coupling elements 432 and 434 of the bracket 418 and the clamp 420 have intermeshing rigid structures 440 and 436, respectively, that slide laterally into locking engagement relative to each other. In the depicted embodiment, for example, the intermeshing rigid structures 440 and 436 are spaced apart rectangular teeth or bars that interpose and interlock with each other when the clamp 420 is slid laterally onto the bracket 418 (as indicated by the directional arrow of FIG. 8). That is, the couplings 432 and 434 are offset from each other so that each tooth or bar of one coupling slides within a space between two teeth or bars of the opposing coupling. In addition, the intermeshing rigid structures 440 and 436 are preferably narrow and closely spaced together for ease in fitting the clamp 420 onto the bracket 418. That is, if the clamp 420 is positioned for sliding onto the bracket 418 and the rigid structures 440 and 436 do not precisely align and allow the clamp to slide onto the bracket, then the clamp need only be moved slightly until the rigid structures do align and allow the clamp to slide onto the bracket.

FIG. 9 illustrates a retainer clamp 520 and a portion of a mounting bracket 518 of a bracket assembly according to a sixth example embodiment. The clamp 520 and mounting bracket 518 are similar to those of the fifth example embodiment just described. In this embodiment, however, the coupling elements have rigid structures that are angled or curved downward to tighten down on the rail as the clamp 520 is slid onto the bracket 518. In the depicted embodiment, for example, the intermeshing rigid structures 536 and 540 of the bracket 518 and the clamp 520 are angled downward from the front of the bracket toward the rear (adjacent the post). As the clamp 520 is slid rearward onto the bracket 518, the downward angle of the intermeshing rigid structures moves the clamp downward relative to the bracket until the retaining surface of the clamp is snugly against the rail.

FIG. 10 illustrates a retainer clamp 620 and a portion of a mounting bracket 618 of a bracket assembly according to a seventh example embodiment. The clamp 620 and mounting bracket 618 are similar to those of the first and fifth example embodiments. In this embodiment, however, the intermeshing rigid structures 636 and 640 of the clamp 620 and the bracket 618 are keyed together in an interlocking arrangement. In the depicted embodiment, for example, the intermeshing rigid structures 636 and 640 are provided by trapezoidal teeth or bars, generally in the nature of a multiple sliding dovetail joint. In alternative embodiments, the intermeshing rigid structures have other shapes such as circular or polygonal heads or tabs that interlock with channels or slots having conforming shapes.

In another aspect, the invention includes the fence system 12 with one or more of the fence posts 16, one or more of the fence rails 14, and one or more of the fence rail bracket assemblies described herein. These fence system 12 components, or only some of them, may be packaged together and sold as kits, or they may each be provided individually.

It is to be understood that this invention is not limited to the specific devices, methods, conditions, and/or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only. Thus, the terminology is intended to be broadly construed and is not intended to be unnecessarily limiting of the claimed invention. In addition, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, plural forms include the singular, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Furthermore, any methods described herein are not intended to be limited to the sequence of steps described but can be carried out in other sequences, unless expressly stated otherwise herein.

Moreover, while certain embodiments are described above with particularity, these should not be construed as limitations on the scope of the invention. It should be understood, therefore, that the foregoing relates only to exemplary embodiments of the present invention, and that numerous changes may be made therein without departing from the spirit and scope of the invention as defined by the following claims. 

1. A fence bracket assembly for use with a fence system including at least one upstanding post and at least one rail that is laterally arranged relative to the post, the bracket assembly comprising: two upstanding sidewalls that receive the rail therebetween, wherein at least one of the sidewalls includes a coupling element; a rear wall that extends from one or both of the sidewalls and is adapted to mount to the post; a bottom wall extending at least partially between the two sidewalls and defining a support surface that supports the rail; and at least one retainer clamp including at least one coupling element that locks to the bracket coupling element without using any tools, wherein the bracket defines an access opening through which the rail can be non-axially inserted onto the bracket, and wherein the at least one clamp defines a retaining surface that blocks the rail from being removed through the access opening when the clamp is locked to the bracket.
 2. A fence bracket assembly as claimed in claim 1 wherein the at least one retainer clamp comprises a clamp that spans from one of the sidewalls to the other of the sidewalls of the bracket assembly.
 3. A fence bracket assembly as claimed in claim 1 wherein the at least one retainer clamp comprises two clamps, one of which engages one of the sidewalls and a second of which engages the other of the sidewalls.
 4. A fence bracket assembly as claimed in claim 1 wherein the at least one retainer clamp is serrated or barbed to releasably secure it to one or both of the side walls.
 5. A fence bracket assembly as claimed in claim 4 wherein the at least one retainer clamp is partially inserted into a socket formed in at least one of the sidewalls.
 6. A fence bracket assembly as claimed in claim 4 wherein the at least one retainer clamp comprises a socket for receiving a barbed or serrated portion of one of the side walls.
 7. A fence bracket assembly as claimed in claim 1 wherein the at least one retainer clamp is secured to one of the sidewalls by moving the retainer clamp vertically relative to the side wall.
 8. A fence bracket assembly as claimed in claim 1 wherein the at least one retainer clamp is secured to one of the sidewalls by moving the retainer clamp essentially horizontally relative to the side wall.
 9. A fence bracket assembly as claimed in claim 1 wherein the at least one retainer clamp is secured to one of the sidewalls by moving the retainer clamp partially horizontally and partially downwardly relative to the side wall.
 10. A fence bracket assembly as claimed in claim 1 wherein the at least one retainer clamp is secured to one of the sidewalls teeth or splines.
 11. A fence bracket assembly as claimed in claim 1 wherein when the at least one retainer clamp is secured to one of the sidewalls, a smooth outer appearance is obtained. 